US9958202B2 - Inerted plate dryer and method of drying solvent based coating - Google Patents

Inerted plate dryer and method of drying solvent based coating Download PDF

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US9958202B2
US9958202B2 US14/237,919 US201214237919A US9958202B2 US 9958202 B2 US9958202 B2 US 9958202B2 US 201214237919 A US201214237919 A US 201214237919A US 9958202 B2 US9958202 B2 US 9958202B2
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solvent
dryer
plate
web
stream
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US20140202028A1 (en
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Juan De Santos Avila
Kostas N. Christodoulou
Ahmad Khodaei
Ali R. Mehrabi
Luigi Sartor
Henk de Koning
George Arkesteijn
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Avery Dennison Corp
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Avery Dennison Corp
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B3/00—Drying solid materials or objects by processes involving the application of heat
    • F26B3/18—Drying solid materials or objects by processes involving the application of heat by conduction, i.e. the heat is conveyed from the heat source, e.g. gas flame, to the materials or objects to be dried by direct contact
    • F26B3/20—Drying solid materials or objects by processes involving the application of heat by conduction, i.e. the heat is conveyed from the heat source, e.g. gas flame, to the materials or objects to be dried by direct contact the heat source being a heated surface, e.g. a moving belt or conveyor
    • F26B21/14—
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B21/00—Arrangements for supplying or controlling air or other gases for drying solid materials or objects
    • F26B21/40—Arrangements for supplying or controlling air or other gases for drying solid materials or objects using gases other than air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B25/00—Details of general application not covered by group F26B21/00 or F26B23/00
    • F26B25/005—Treatment of dryer exhaust gases
    • F26B25/006—Separating volatiles, e.g. recovering solvents from dryer exhaust gases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B13/00—Machines and apparatus for drying fabrics, fibres, yarns, or other materials in long lengths, with progressive movement
    • F26B13/10—Arrangements for feeding, heating or supporting materials; Controlling movement, tension or position of materials
    • F26B21/04—
    • F26B21/12—
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B21/00—Arrangements for supplying or controlling air or other gases for drying solid materials or objects
    • F26B21/20—Circulating air or gases in closed cycles, e.g. wholly within the drying enclosure
    • F26B21/25—Circulating air or gases in closed cycles, e.g. wholly within the drying enclosure partly outside the drying enclosure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B21/00—Arrangements for supplying or controlling air or other gases for drying solid materials or objects
    • F26B21/30—Controlling, e.g. regulating, parameters of gas supply
    • F26B21/37—Velocity of flow; Quantity of flow
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B25/00—Details of general application not covered by group F26B21/00 or F26B23/00
    • F26B25/008—Seals, locks, e.g. gas barriers or air curtains, for drying enclosures

Definitions

  • the present invention relates to an apparatus and method for drying liquid coatings on a substrate. More particularly, the invention is directed to an inerted plate dryer and its use in drying solvent based coatings.
  • Drying or curing of liquid coatings on a substrate or web is typically achieved by passing the substrate through a drying chamber, in most cases, a conventional oven (either a floatation or roller supported oven), where the liquid is evaporated and the coating is dried or cured.
  • the oven is heated with heating elements.
  • the heat is passed onto the coating through convection or forced gas flow, typically air. Multiple zones of the oven may be employed to allow flexibility in the temperature adjustment.
  • regulations impose a maximum concentration of the solvent allowable in the drying chamber to ensure safety of operation.
  • This maximum concentration is defined in terms of a fraction or most often as a percentage (% LEL) of the lower explosive limit (LEL) of the solvent or mixture of solvents removed from the coating undergoing drying or curing.
  • LEL is the lowest concentration where a conflagration or explosion can be propagated from an initially ignited point; LEL is a property of the solvent or solvent mixture, whereas % LEL is just a measure of concentration of a particular solvent or solvent mixture referred to the LEL of that solvent or solvent mixture.
  • the maximum allowed solvent concentration in a given dryer (in terms of % LEL) that a dryer is allowed to safely handle by regulation ultimately does limit substrate or web speed.
  • the solvent removed from the coating is either condensed into liquid form through a condensation system, or more commonly burned by a thermal oxidation unit (TOX).
  • a condensation system When a condensation system is used, it often includes a tandem of condensers, typically and needs to operate at a low temperature (below 0° C.) to condensate most of the solvent, with a correspondingly high demand on energy.
  • a TOX unit When a TOX unit is used, there is a maximum amount of solvent per unit time that can go through a TOX due to safety (explosivity, which constrains solvent concentration, and energy release, i.e. maximum operating temperature, which constrains the throughput). This imposes a limit on the solvent content out of the combined streams sent to the TOXs, and therefore ultimately imposes a limit on the maximum substrate speed through the oven.
  • blistering i.e., appearance of bubbles in the dried coating. It is caused by rapid bubble growth from gases dissolved or entrained in the coating liquid and from the volatile solvents in the coating, which exhibit a high vapor pressure.
  • temperature and speed of the gas commonly air is reduced, typically in the first zone(s) of the oven when multiple zone are used.
  • a plate dryer Another type of dryer that can be used for drying liquid coatings is a plate dryer. They may include heated plates at one or both sides of a moving web. They have been used in pultrusion and other curing processes. In these applications process velocities are low ( ⁇ 30 m/min). Typical flows of the inerted gas-solvent mix are in the range of 1 m/s with low external mass transfer and heat transfer, which makes it not suitable for higher speed coating lines.
  • U.S. Pat. No. 4,894,927 assigned to Fuji Photo, teaches the benefits of a low volume inerted plate dryer and how the system can include solvent recovery by condensation and how heat can be recovered by placing a heat exchanger between the dryer and the condenser.
  • U.S. Pat. No. 4,926,567 also assigned to Fuji Photo, teaches how the incoming inert stream can be heated by heat exchange with the exhaust of an incinerator where the recovered solvent is burned.
  • Neither patent teaches how the systems are sealed to avoid contamination of the ambient air to the heater and vice versa. Nor do they teach what conditions are needed for the system to be beneficial.
  • both patents consider that the entire dryer exhaust stream undergoes condensation.
  • One type of plate dryers is designed with internal condensing surfaces, which are sometimes referred to as “gap dryers”.
  • this type of dryer heat is provided by a hot plate or any other suitable source.
  • the carrier web moves over the plate or close by.
  • Condensation occurs inside the dryer, over a cold surface that creates a concentration gradient that drives significant diffusion of the solvent.
  • U.S. Pat. No. 5,581,905 (and sequels) assigned to 3M teaches substantially horizontal configurations of the plates where the cold surface is kept as close as ⁇ 0.5 cm above the drying wet coating. Condensation occurs on the lower surface of the cold top plate which is grooved such that capillarity drives the liquid out towards the edges where it is drained. No significant convective gas flow occurs inside the dryer apart from that induced by web drag. There is the possibility of solvent dripping over the drying coating, as well as water condensation if air enters the system.
  • the present invention is directed to an inerted plate dryer and the method of using it to dry organic solvents-based coatings.
  • an apparatus for drying a continuous moving web carrying a liquid layer comprises: a housing enclosing a drying chamber, said housing having entry and exit slots through which said web may be passing through said chamber; said entry and exit slots having a sealing mechanism to prevent leakage of ambient air into the drying chamber, or leaking out of the gas stream from the chamber into the ambient; a bottom heated plate and a top heated plate aligned substantially parallel to each other with a space between them, said space is no more than 10 cm distance apart and preferably less than 5 cm apart, and most preferably between 0.5 to 5 cm apart; at least one inlet for a gas stream to flow into the chamber with a velocity, said velocity is between 2 m/s and 20 m/s, and preferably 6-15 m/s, flowing mainly in either the direction of the substrate movement, i.e. co-current, or against the direction of the substrate movement, i.e. countercurrent; at least one outlet for an exhaust to flow out of the chamber, wherein the carrier web is closer to
  • a method of drying a continuously moving web carrying a liquid comprises passing the web through an enclosed dryer via entry and exit slots communicating wherewith; heating the web from both top and bottom using a top and a bottom heated plates, with said web located closer to the bottom heated plates; passing a gas stream from at least one inlet and flowing over the web at a velocity at least 2 m/s to generate an exhaust; discharging the exhaust through at least one outlet; dividing the exhaust into a condensing stream and a by-pass recycled stream; passing the condensing stream through a condenser to generate a liquid condensate and a solvent stripped stream; and mixing the recycled stream with the stripped stream and a make-up inert gas stream to form a inlet gas stream.
  • a method of drying a continuously moving web carrying a liquid comprises passing the web through an enclosed dryer via entry and exit slots communicating wherewith; heating the web from both top and bottom using a top and a bottom heated plates, with said web located closer to the bottom heated plates; passing a gas stream from inlets located close to each one of the entry and exit slots and flowing over the web, towards the middle of the dryer in co- and counter-current streams, at a velocity at least 2 m/s to generate an exhaust; discharging the exhaust through one outlet situated at the middle of the dryer; passing the condensing stream through a condenser to generate a liquid condensate and a solvent stripped stream; and mixing the recycled stream with the stripped stream and a make-up inert gas stream to form a inlet gas stream.
  • a method of drying a continuously moving web carrying a liquid comprises passing the web through an enclosed dryer via entry and exit slots communicating wherewith; heating the web from both top and bottom using a top and a bottom heated plates, with said web located closer to the bottom heated plates; passing a gas stream from a inlet located close to the middle of the dryer, splitting into co- and countercurrent streams, and flowing over the web, towards each dryer extreme, at least 2 m/s to generate exhausts; discharging the exhausts through outlets situated close to each one of the entry and exit slots; dividing the exhausts into a condensing streams and a by-pass recycled streams; passing the condensing streams through a condenser or condensers to create condensate stream(s) and solvent stripped stream(s); and mixing the recycled streams with the stripped streams and a make-up inert gas stream to form a inlet gas stream.
  • a method of drying a continuously moving web carrying a liquid comprises passing the web through an enclosed dryer via entry and exit slots communicating wherewith; heating the web from both top and bottom using bottom heated plates and at least one special unit atop, with said web located closer to the bottom heated plates; the special units atop can be but are not limited to IR lamps, UV lamps, electron beam emitters, radio frequency emitters, ultrasound sources, etc.
  • FIG. 1 is a schematic drawing of an exemplary embodiment of the invention
  • FIG. 2 is a schematic drawing of a seal (sluice) for an exemplary embodiment of the invention
  • FIG. 3 is a schematic drawing of an exemplary embodiment of the invention.
  • FIG. 4 is a schematic of the gas flow
  • FIG. 5 is a schematic of the gas flow in an alternative configuration
  • FIG. 6 is a schematic of the gas flow in an alternative configuration. Unless otherwise indicated, the illustrations in the above figures are not necessarily drawn to scale.
  • an embodiment of the invented inerted plate dryer 10 comprises a housing 140 , a drying chamber 150 enclosed by the housing, an entry slot and an exit slot 160 where a moving web 120 with a liquid coating layer 130 will be passing through the chamber through the entry and exit slots.
  • At least one inlet 191 and at least one outlet 192 are located on the housing.
  • the present invention contemplates that the at least one inlet 191 comprises a nozzle and the nozzle is pointed towards the direction of the at least one outlet 192 .
  • Gas stream 200 flows into the drying chamber through the inlets and the solvent laden exhaust 300 flows out of the chamber through the outlets.
  • Entrance and exit seals 110 serve to minimize both the entrainment or convection of ambient air into and the solvent laden exhaust out of the oven.
  • a seal may include inerted gas streams issued from either or both faces of the seal, to improve containment.
  • a fraction of the solvent laden stream 300 that may circulate between the heated plates of the present invention may be fed to an exit seal.
  • the present invention contemplates that in one embodiment the gas that is fed through the exit seal may be captured by a draft of an upstream conventional dryer having an entrance that is kept at sub-atmospheric pressure, via a suitable connecting tunnel.
  • a condensing system 20 Downstream to the inerted plate dryer, a condensing system 20 can be used to condense the solvent out of the exhaust.
  • the solvent stripped stream can then go through a fan and heat exchanger or recuperator before it is sent back as the inlet gas stream.
  • a make-up amount of inert gas may be added to the inlet stream. This make-up stream may be a fraction of the inert gas fed to the seals at the dryer extremes.
  • top heated plate refers to the heated plate that faces the liquid coated side of the web or substrate.
  • bottom heated plate refers to the heated plate that faces the other side of the web or substrate.
  • the oven can be made inert by saturating it with a proper inert gas, and by maintaining an Oxygen concentration under a critical value, typically at approximately 8% by volume or below.
  • Table 1 lists the maximum oxygen concentration in percentage of volume below which explosion or deflagration or the gaseous mixture containing a solvent can't occur.
  • fresh inert gas would be provided at the entrance seal and additionally in the recirculation system if needed.
  • the system must be equipped with an appropriate number of O2 sensors so to effectively monitor the O2 concentration within the oven chamber and the recirculation ducts.
  • the 90% response time of the monitoring system should be preferably less than 20 s, meaning that the system will signal 90% of the magnitude of a change in concentration within 20 s from its occurrence.
  • the system can be set to alarm at a much lower level, such as 3% of oxygen by volume, and trigger a coater shut-down at 4% oxygen by volume.
  • the inert gas can be any appropriate gas, such as nitrogen or CO2. Due to low or no oxygen concentration, the risk of explosion and fire is greatly relieved and therefore, the restriction on the amount of solvent in the gas stream is no longer relevant. This leads to one advantage of the inerted plate dryer where higher percentage of solvent can exist in the gas stream inside the drying chamber. Therefore a significant portion of the solvent in the exhaust stream can be recycled back into the dryer. The demand on the downstream condenser is greatly relieved as lesser amount of solvents need to be condensed.
  • the existence of higher amount of solvent vapor in the gas stream has another benefit: it relieves blistering and delivers defect free coating.
  • the maximum amount of solvent vapor that can be used in the gas stream depends on the type of solvent.
  • the presence of the most volatile solvents in significant concentrations but quite below the saturation concentration, will alleviate blistering by inhibiting the evaporation of the most volatile solvents without a drastic reduction of drying capacity.
  • some of these most volatile solvents are good solvents, they will plastify the upper layer of the coating being dried, avoiding or delaying transfer skinning (formation of a dense layer that exhibits strong resistance to solvent transfer), and therefore will alleviate the blistering consisting of bubbles trapped by the skin layer.
  • the inerted plate dryer can be also be beneficial when operated as a deaerator.
  • operating the inerted plate dryer with the inerted gas stream saturated or close to saturation with solvent will inhibit solvent evaporation, while heating the liquid coating will facilitate the escape of the dissolved or entrained gas.
  • These conditions are also the better suited for the liquid coating to heal if there were bubble bursting.
  • the entry and exit slots 160 need to be properly sealed.
  • One embodiment of the invention uses seals with top and bottom faces close enough to the coated substrate to minimize entrainment or convection of ambient air into that oven and the escape of solvent laden gas out of the oven.
  • a substrate 120 coated with a liquid layer 130 enters or exits the seal mechanism (or sluice) 110 through the slot 160 .
  • the slot 160 may be a narrow passage specifically for the substrate.
  • Either one or both of top and bottom parts of the seal can be made movable perpendicularly to the coated substrate.
  • a control mechanism can be set up so that the top seals at the entrance and exit can open up, preferably to 15 to 30 mm to allow for the passage of splice or any other gross defect that would interfere with the entrance or exit clearance.
  • This control mechanism can include a signal that is provided both by the liner unwinder splice actuator, and by events in the coating head, for example, a reverse roll back-up roll nip opening, or the withdrawal of a coating die.
  • the seals are preferred to open at an appropriate delayed time. Also, it is desirable to be able to manually give a signal for the seal opening at any time.
  • the opening of the seals must be appropriately coordinated with the gas flow control of the oven, so not to loose inertization of the oven over a short (less than 10 s) open time.
  • the seals When in position, the seals will be fixed, e.g. via springs/pressure, so that they can be pushed open by an unforeseen interference due to an obstruction carried by the web, or an undetected splice. This will avoid severe damage to the seals.
  • narrow opening other methods can also be used to prevent leakage at the entrance or exit slots, such as impinging jets, inerted gas curtains, labyrinths, conditioning chambers, gas extraction slits, etc.
  • impinging jets inerted gas curtains, labyrinths, conditioning chambers, gas extraction slits, etc.
  • the slits can be angled for improved containment and isolation of the drying chamber 150 from the exterior environment.
  • the slits 420 could deliver a couple of N2 planar jets (one from the top and one from the bottom of the web) which will uniformly cover the entire width of the web.
  • the oven exit seals would also have similar jets. These exit seal jets can be fed at a desired flow rate to preclude entrance of O2 to the oven.
  • the exit seal may use process N2 from the inerted dryer recirculation loop (polluted with organic solvents vapor) provided that the solvent laden gas issued by the exit seal is delivered to the entrance of the conventional oven through a connecting enclosure.
  • the gas stream can be fed into the heating chamber in concurrent or counter-current directions with respect to the moving coated substrate.
  • co-current feeding the gas stream comes in through inlets near the substrate entrance, and the exhaust is discharged through the outlets near the substrate exit.
  • countercurrent feeding the gas stream comes in through inlets near the exit, and is discharged through the outlets near the entrance.
  • An initial co-current followed by counter current feeding can be achieved through feeding through inlets near both entrance and exit slots, and discharging through an outlet in the middle of the chamber.
  • an initial counter-current followed by co-current feeding can be achieved through feeding through an inlet at the middle of the dryer and discharging through outlets near both entrance and exit slots.
  • a single inerted plate dryer can include a multiplicity of co-current and countercurrent sections, with the adequate placement of inlets and exhausts for the gas stream.
  • the direction of feeding does impact the interaction between the hot inerted gas stream and the coated liquid layer and therefore the drying history of the coated layer and, in consequence, the efficiency of drying.
  • FIG. 4 is a schematic drawing of how gas flowing in and out of the inerted plate dryer.
  • Fresh inert gas 601 is fed to the seals 110 to improve containment. Part of these inert streams enters the inerted oven and part is released to the atmosphere. If so required as make-up a fresh inert gas 610 is mixed with a certain amount of by-passed exhaust 617 and solvent stripped stream 620 to make the stream 630 , which can be conditioned by a heat exchanger to make the feed 635 .
  • the exhaust 650 is split into two streams 616 to be condensed and 617 as the bypass.
  • Stream 616 cools down, through a heat recuperator, to stream 618 that passes through a condenser to have to solvent 680 collected into a solvent tank.
  • the rest of the stream 616 including the inerted gas and the un-condensed solvent makes up stream 619 which is then split into a small stream 662 to be purged to TOX and the stream 626 which then goes through a heat recuperator to give the warmed solvent stripped stream 620 which is mixed with the by-passed exhaust and fresh inert gas to become the stream 630 which after heating up becomes the feed 635 , as described in the beginning of this section.
  • the gas flows through the drying chamber at a high gas velocity, pressure drop through the drying chamber can be significant.
  • FIG. 5 is a schematic drawing of how gas flowing in and out of an alternative configuration of the inerted plate dryer. Fresh inert gas 601 is fed to the seals 110 to improve containment.
  • a fresh inert gas 610 is mixed with a certain amount of by-passed exhaust 617 and solvent stripped stream 620 to make the streams 630 and 631 , which can be conditioned by heat exchanger(s) to make the feeds 635 and 636 .
  • the exhaust 650 is split into two streams 616 to be condensed and 617 as the bypass.
  • Stream 616 cools down, through a heat recuperator, to stream 618 that passes through a condenser to have to solvent 680 collected into a solvent tank.
  • FIG. 6 shows two outlets situated close to the entry slot and the exit slot of the housing and the inlet is situated at the middle of the chamber.
  • FIG. 6 shows warmed solvent stripped stream 620 is mixed with the by-passed exhaust and fresh inert gas to become stream 632 , which after heating becomes the feed 637 .
  • the exhausts 651 and 652 are combined and then split into two streams 616 to be condensed and 617 as the bypass.
  • a single inerted plate dryer unit can comprise one or more co-current and countercurrent inerted gas stream section, with the placement of multiple feed and exhaust ports for the inerted gas stream.
  • the top heated plate and the bottom heated plate can be heated through any suitable mechanisms known by person skilled in the art.
  • the plates can be single units or arrays of smaller plates, as may be required to accommodate a curved path, and also to allow flexible temperature control.
  • Each heated plate or plate array can have one or multiple heating zones. The temperature of each zone can be adjusted independently, so that, for example, temperatures of plates atop the web can be different from that of the plate under the web, or one of these plates can be heated and the other set at ambient temperature. The temperature can also vary from one zone to another for the same plate or plate array along the web path.
  • top plates may be substituted totally or partially or be intercalated by special units such as IR lamps, UV lamps, electron beam emitters, radio frequency emitters, and ultrasound sources (shown as item 180′ in FIG. 1 ).
  • the gap h between the two plates is kept at a small number to ensure efficient heat transfer, and high enough gas velocity inside the chamber.
  • Such inter-plate gap is preferred to be no more than 10 cm apart. It is even more preferred to be less than 5 cm apart and it is most preferable when it is between 0.5 and 3.5 cm.
  • the plate spacing near the extremes can be larger than in the rest of the dryer to accommodate the feed and exhaust assemblies as well as the mounting of the seals.
  • the moving web is positioned in between the two heated plates, being closer to one of the plates, preferably the bottom plate.
  • the distance h2 between the bottom heated plate and the moving web should be kept as small as possible. It is preferred to be less than a 20 mm. It is even more preferred to be less than 10 mm.
  • the distance h1 between the top heated plate and the moving web should also be kept to be no greater than a few cm. It is preferred to be less than 5 cm.
  • the plates can have a mechanism that allows adjustment of the distance between the corresponding top and bottom plates. The distance from the bottom plate to the web, which can move over rollers, can be set by adjusting the bottom plate.
  • the top and bottom heated plates may be angled with respect to each other.
  • the angle between the top and bottom plates can vary along the path of the web for best drying effect or accommodating other accessories.
  • These sections where the top plates and the bottom plates are at an angle to each other may be used to control the pressure along the inerted gas stream path as kinetic and pressure energy are exchanged, with certain losses, in the converging & diverging passages that the plates create.
  • kinetic and pressure energy are exchanged, with certain losses, in the converging & diverging passages that the plates create.
  • converging & diverging passages that the plates create.
  • greater velocity in the narrower sections would enhance heat transfer and the associated mass transfer.
  • each heated plate can be smooth, or textured. Textures can be designed to enhance mixing (likely turbulent atop the substrate and laminar between the substrate and the bottom plate) to enhance mass and heat transfer rates inside the chamber.
  • the textures on the bottom plate can also be designed to create a laminar layer between the bottom plate and the web such that the web can move as close as possible to the heated plate without actually touching the plate. Eddies in cavities on the lower plate can also be used to increase or maintain high enough heat transfer rates.
  • the simplest texturing is shallow slots running across the plates' width. Also, localized depressions can be produced on the plate surface, in a staggered pattern with respect to the direction of flow of the inerted gas stream (or machine direction).
  • fixtures can be mounted over the plates, as thin strips running across the plates' width.
  • other shapes such as but not limited to thin discs, ovals or tear shaped flats could be mounted in a staggered pattern, in the machine direction, to enhance secondary flows. If these fixtures are made of soft material, they can be used to support the substrate, which would slide over the fixtures, instead or in addition to rollers
  • multiple inerted plate dryers can be used along the web moving direction. This can be effective when just one inerted plate dryer would not be able to dry the coating satisfactorily, even with optimized operating conditions.
  • the design length of a single inerted dryer zone is ultimately limited by pressure drop through the drying chamber, which may reduce the effectiveness of the seal. Also when an oven length is too long high solvent concentration can accumulate in the gas stream, which would deteriorate mass transfer on the remaining length of the oven and make the oven ineffective.
  • the inerted plate dryer of the current invention can be used as a stand-alone drying unit, or as an add-on to an existing installation, due to its smaller volume and slender size. For example, it can be positioned before a conventional oven.
  • the inerted plate dryer can be used to flash out a significant amount of solvent from the initially solvent-rich coating to deliver a partially dried coating to the conventional oven, and therefore relieve the amount of solvent to be handled by the downstream conventional oven and the installed TOX. Therefore, the use of the inerted plate dryer as a first drying zone can increase overall drying efficiency for a given total length of oven. This can be advantageous when used to increase capacity of older assets.
  • FIG. 3 illustrate such an exemplary usage of the inerted plate dryer.
  • the inerted plate dryer 10 is placed after the coating station 40 , in the fly-up of the substrate 120 to a conventional oven.
  • the inerted plate dryer is shorter that this minimum length, it is not beneficial because either a) the dried coating at the end of the dryers retains a high solvent concentration, at low temperatures of the inerted gas stream and heated plates, and/or b) blistering is induced inside the inerted plate dryer and/or solvent concentration is exceeded in the following conventional dryer as the temperatures of the inerted gas stream and/or heated plate are increased.
  • the drying efficiency as measured by the maximum speed at which a given coating can be dried, can reach a maximum as the ratio of inerted plate dryer length to overall oven length is increased; this would happen when the conventional dryers exhibits better heat and mass transfer efficiencies, as modern high speed floatation ovens are bound to have, despite their LEL limitation, which in any case becomes irrelevant at the latter stages of drying. Therefore, there is an optimal window for design and operation of an inerted plate dryer.
  • Table 2 is an example of operating parameters to demonstrate the concept of a minimum length of the plates.
  • the inerted plate dryer is placed before a conventional oven with multiple zones.
  • the amount of solvent in the coating upon entering zone 1 of the conventional oven is calculated as a percentage to the lower explosivity limit (LEL) allowed at the operating condition in the ensuing conventional zone 1.
  • LEL lower explosivity limit

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  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
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EP2742302B1 (en) 2017-05-03
WO2013023058A2 (en) 2013-02-14
US20180195796A1 (en) 2018-07-12
ES2625072T3 (es) 2017-07-18
WO2013023058A3 (en) 2013-05-02
EP2742302A2 (en) 2014-06-18
PL2742302T3 (pl) 2017-10-31
CN103890518A (zh) 2014-06-25
US20140202028A1 (en) 2014-07-24

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